Method of making and installing a ventillating air distribution channel

ABSTRACT

The supporting grid (e.g., main and cross inverted tees) of a suspended ceiling also completely supports ventilation airdistributing apparatus including the air supply duct. This apparatus comprises a lower air flow channel section formed of two extruded metal bars having vertical webs with hooks on the outside of the web defining ways into which the wings of a bracket project to hold the spaced bars in a channel assembly. Along the top of the web of each bar are two outwardly extending spaced arms which are used to hold the sides of a fiberglass air duct. With the exception of the brackets and optional air extractor, all component parts are brought together into subassemblies at the factory and shipped flat in stacks to the job where assembly of the duct-channel units is completed by the simple operation of folding the ducting and inserting the brackets at the ends of the channels to hold the unit together for mounting in the grid structure.

United States Patent Rachlin et al.

[ 1 METHOD OF MAKING AND INSTALLING A VENTILLATING AIR DISTRIBUTIONCHANNEL [76] Inventors: Joel R. Rachlin, 1785 Wedgewood West, Elm Grove,Wis. 53122; Rudolph O. Neudek, W271Nl275 Meadowbrook Road, Waukesha,Wis. 53186 [22] Filed: July 3, 1972 [21] Appl. No.: 268,512

Related US. Application Data [63] Continuation-impart of Ser. No.10,508, Feb. 1 1,

1970, Pat. No. 3,673,945.

[52] US. Cl. 52/745; 52/220; 52/495;

[51] Int. Cl. E04B 5/52; F24F 7/04; F24F 13/06 [58] Field of Search52/495, 741, 745, 631;

98/40 D, 40 DL; 29/469; 93/4l.l

[56] References Cited UNITED STATES PATENTS 2,555,530 6/1951 Bell et a1.1 29/469 3,132.579 5/1964 LuVigne et a1... 98/40 D 3,177,796 4/1965 Leeet 98/40 D 3,187,661 6/1965 Dail 98/40 D 3,241,280 3/1966 Kreuzer 52/495X 3.331305 7/1967 Oneson 98/40 D 3,353,472 11/1967 Lee et a1. 93/40 D3,353,473 1 1/1967 Oneson et ul 98/40 D 1 Oct. 14, 1975 3,397,499 8/1968Wart 52/630 x 3,420,142 l/1969 01116 et al. 93/94 PS 3,577,904 5/1 71Lambert 98/40 1) 3,001,032 8/1971 Lambert 98/40 D 3,601,033 8/1971Lambert 98/40 12 Primary ExamitierFrank L. Abbott AssistantExaminerLeslie A. Braun Attorney, Agent, or FirmDarbo, Robertson &Vandenburgh ABSIRACT The supporting grid (e.g., main and cross invertedtees) of a suspended ceiling also completely supports ventilationair-distributing apparatus including the air supply duct.'This apparatuscomprises a lower air flow channel section formed of two extruded metalbars having vertical webs with hooks on the outside of the web definingways into which the wings of a bracket project to hold the spaced barsin a channel assembly. Along the top of the web of each bar are twooutwardly extending spaced arms which are used to hold the sides of afiberglass air duct. With the exception of the brackets and optional airextractor, all component parts are brought together into subassembliesat the factory and shipped fiat in stacks to the job where assembly ofthe duct-channel units is completed by the simple operation of foldingthe ducting and inserting the brackets at the ends of the channels tohold the unit together for mounting in the grid structure.

5 Claims, 6 Drawing Figures U.S. Patent Oct. 14, 1975 Sheet 2 on3,911,639

Sheet 3 of 3 U.S. Patent Oct. 14, 1975 METHOD OF MAKING AND INSTALLING AVENTILLATING AIR DISTRIBUTION CHANNEL RELATED APPLICATION Thisapplication is a continuation-in-part' of application Ser. No. 10,508,filed Feb. 11, 1970 now U.S. Pat. No. 3,673,945, dated July 4, 1972. Itrelates particularly to a method of making and installing theductchannel units.

BACKGROUND AND SUMMARY OF THE INVENTION Various forms of structures havebeen proposed and used for providing ventilating air distribution inconnection with suspended ceilings. The systems in commercial use sufferfrom a common disadvantage; namely, they must be assembled (to a greateror lesser extent) at the ceiling level. This is difficult and awkward todo. lnevitably, it results in very high labor costs. At the very minimumthey require the installation and attachment of wires, rods, or othersupports to the air duct and distribution apparatus while the latter isotherwise being held in place. Great care and skill is needed toproperly install the structures.

Also, in known systems, installation requires measuring and cutting andotherwise fitting of materials and parts in expensive custom manner. Thebill of materials for a given job requires considerable figuring toarrange for a balanced and adequate supply of materials and parts. Thesystems and installation, procedures are geared to now obsolete scalesof building trade labor costs.

The principal object and advantage of the present invention is toprovide a simplified air-distributing apparatus which may be completelyassembled at a convenient working location (on a bench or even on thefloor) and then merely liftedinto place and deposited on the ceilinggrid structure. Of paramount importance, expensive field labor isreduced to an almost absolute minimum by factory subassemblying theunits so that only folding of the ducting along prepared fold lines andinsertion of brackets at the ends of the channels is all that is neededon the job.

A further object is to provide ceiling air-distributing apparatus whichis characterized by modular dimensioning and interacting componentswhich makes possible efficient packaging, storage, handling andshipping, as well as installation.

A very real and important object and achievement of the invention is thesaving of upwards of one-half of the field labor installation costs ascompared with known contemporary systems.

Other objects and advantages will become apparent from the followingdescription.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of portions ofan installation utilizing one embodiment of the invention;

FIG. 2 is a sectional view illustrating the embodiment of FIG. Iemployed in a ceiling wherein the airdistributing apparatus is flushwith the surface of the ceiling;

FIGv 3 is a perspective view of an example of a fiber glass ductsection;

FIG. 4 is a perspective view of one of the brackets used for supportingthe apparatus from grid tees;

FIG. 5 is a perspective view of a stack of subassemblies ready on thejob for final assembly;

FIG. 6 is a perspective view of the stack showing the top unit assembledand ready for installation.

DESCRIPTION OF SPECIFIC EMBODIMENTS The following disclosure is offeredfor public dissemination in return for the grant of a patent. Althoughit is detailed to ensure adequacy and aid understanding, this is notintended to prejudice that purpose of a patent which is to cover eachnew inventive concept therein no matter how others may later disguise itby variations in form or additions or further improvements. The claimsat the end hereof are intended as the chief aid toward this purpose, asit is these that meet the requirement of pointing out the parts,improvements, or combinations in which the inventive concepts are found.

FIG. 1 illustrates the use of an embodiment with a ceiling systemcomprising conventional grid of longitudinal (main) tees'15 andcross-tees 16, with ceiling tiles 17. The tees conventionally have abottom flange 18 on each side and a bulbous head 19. Any conventionalmeans, such as wires (not shown), for supporting main tees 15 may beemployed.

In this embodiment of the invention two bar members, generally 21 and22, are employed. These bar members are formed from extruded metal,e.g., aluminum. They are identical and one has been turned end for endwith respect to the other so that one forms a left and the other forms aright. Describing, specifically, the bar on the left in FIG. 1, thesection from which the bar member is formed comprises a vertical web 23,having at the lower end thereof an inwardly extending flange 24 and anoutwardly extending flange 25. A longitudinal rib forms what may betermed afinger 26 extending upwardly in spaced relation to web 23. Ahooked rib forms an upper finger 27. These two ribs, equally spaced fromweb 23, define a partially enclosed way for receiving the wings of themounting brackets, as hereinafter described. An inwardly extending ribforms a shelf 28. Extending upwardly from the top of web 23 is anangular arm 29. A second arm 30 extends outwardly from web 23 in spaced,parallel relation to arm 29.

Adjacent the distal edge of the exterior bottom flange 25 is adownwardly extending support member 31 having a rib 32 along the bottomthereof.

To support the bar members 21 and 22 in proper relation to each otherand form the air-distributing channel, and to mount the channel on thetees 15, a pair of brackets, generally 35, are employed (as best seen inFIGS. 1, 4 and 10); Bracket 35 is formed from sheet metal and includes aplate 36 which eventually lies alongside the vertical portion of thetee. Extending outwardly at right angles from plate 36 are a pair ofwings 37 and 38. These wings are of a size to be received and securelyretained in the ways defined by fingers 26 and 27 of the bars. Whenfully inserted in the ways, the web 23 of the bar members abuts the mainplate 36 of the bracket.

Extending upwardly from the main plate 36 is a clip portion in the formof a bar 39 with three grippers 40, 41, 42 integral therewith. Thegrippers 41 and 42 are spaced apart by gaps equal to their individuallengths and are disposed eccentrically with respect to the center lineof the bracket (as it exists midway between wings 37 and 38). Thepositioning is such that when the two brackets are applied to oppositesides of a supporting grid tee (see FIGS. and the grippers from the twosides interdigitate so that opposite wings of the two brackets on eachside of the tee are in exact alignment. The lower portion 39a of the bar39 fits under bulbous head 19 of the tee when the bracket is mountedthereon. This, in combination with the gripper 42 extending around thetop of the head 19 and down partially over the far side, provides asecure gripping of the tee by the bracket.

A section of fiberglass ducting is used for the air supply duet. This isconventional ducting material which may be formed to the shape mostconvenient for the particular installation. Two folds 45 (FIG. 3) toform a triangular duct is usually the simplest. This triangular duct hasa top 46 and twosides 47 and 48. The lower portions 47a and 48a of thetwo sides are inserted into the two slots defined by the spaced arms 29and 30 of the bars 21 and 22. To facilitate this, the upper portions ofarms 29 are outwardly curved, indicated at 29a. The upper portion of arm30 has an inwardly extending taper 30a extending to a step 3012. A ductretainer, generally 49, is applied to the sides of the duct before thelatter is put into place. This retainer comprises a length of sheetmetal having a bottom flange 50, a side 51 formed with an outwardlyprojecting detent 52, inwardly projecting prongs 53 and an upper releaselever 54. These duct retainers 49 are applied to the edges of the ductwith the prongs 53 being pressed securely into the fiberglass ductmaterial. As the duct with its retainers then is inserted between thearms 29 and 30, the resilient fiberglass material being somewhatcompressed in the process, the detent 52 ultimately snaps into placebehind step 3012 so as to securely lock the fiberglass duct to the barmembers 21 and 22, the joint being self sealing against air leakage.Inward pressure on release lever 54 will disengage detent 52 from step30b and permit removal of the duct from the channel.

Shutters, generally 55, are employed on inner flanges 24 to serve asdampers for the regulation of the air flow. These shutters are formed ofcontinuous lengths of sheet metal bent into a U so as to have an upperplate 56 and a lower plate 57. These plates frictionally grip the innerflanges 24. The inner flanges may be formed with grooves 24a into whichthe detent end 56a can seat at a variety of positions. The end 57a isbent outwardly to form a handle to facilitate the manipulation of thedamper from the room below the ceiling.

Between the bar members 21 and 22 is an air extractor, generally 58(FIGS. 1 and 2). It comprises a plate 59, the longitudinal edges ofwhich have been bent down to form flanges 60. Along the center portion aplurality of three-sided cuts were made with the metal within the cutareas being bent down to form a series of deflectors 61 and leavingopenings 62 in the metal. The function of the extractor is to turn airdownwardly when supplied for linear flow through the duct.

Along the under side is a cap or grille, generally 64, also preferablyformed by metal extrusion. Along the under side, the cap has a centerrecess 65, into which the upper edge of a partition may be inserted ifthe area being ventilated is divided into rooms. A divider 66 extendsupwardly at the center line of the cap and has an arrowhead ridge 67along the top thereof. At each side of divider 66 the cap is providedwith a plurality of openings 68. Along each side are upwardly extendingsupport flanges 69 having hooks 70 (FIG. I along the inner sidesthereof. These hooks 70 are for engaging the bulbous ridges 32 ofsupportmembers 31 to hold the cap in place.

It is the common practice to position the longitudinal tees 15 on fourfoot centers. Accordingly, the bar members 21 and 22, the extractor 58,the duct sections 46-48, the duct retainers 49 and the shutters 55 wouldbe cut into, and supplied in, 4 foot lengths (orjust that amount shortof 4 feet to allow for the thickness of the metal at each side of thecenter line of the tees). The caps may also be supplied in lengthsexactly 4 feet long.

The air-distributing apparatus illustrated in FIG. 2 is identical withthat already described. However, FIG. 2 illustrates the manner in whichthis system is employed in connection with a ceiling of the type whereinthe ceiling tiles 76, instead of resting on the exposed flanges 77 ofthe tees, have slots 78 into which the flanges 77 extend. In thisarrangement the tiles 76 that are to rest on flanges 25 of theair-distributing channels are notched out so that when the tile is inplace it will be horizontal. The flanges 25 and the flanges 77 are atthe same elevation whether the tiles and ceiling arrangement are of thetype illustrated in FIG. I or the type illustrated in FIG. 2, but in thelatter the supporting grid structure is hidden from view.

While the hardware for a single unit may be packaged together, assembledor unassembled, and so supplied to the job, maximum overall economy isachieved, in accordance with the present invention, by bringing togetherat the factory all channel-forming parts, with the single exception ofbrackets 35, and attaching these parts to the respective side edges of asheet of ducting to form subassemblies that may be stacked flat andshipped to the job for minimum field assembly and installationoperations. Such a stack 80 is illustrated in FIG. 5 resting upon apallet 81. As is in dicated by tapes 82, the stack may be fastenedtogether and ma pallet at the factory for safe shipment to the joblocation.

As is shown, each flat subassembly 83 comprises a rectangular sheet 84of fiberglass ducting having shallow V grooves 85 cut therein toestablish fold lines and provide the necessary material clearance forfolding the fiberglass sheet to form the triangular duct as illustratedin FIG. 3. The two bar members 21 and 22 carrying shutters 55 (not shownin FIG. 5) are mounted upon the edge portions of fiberglass ducting 84with the aid of clips 51 (not shown in FIG. 5). Thus, all of thecomponent parts for one-half of the eventual air-flow channel aremounted upon each of the sides of the eventual duct, each set of partsbeing identical to the other but so designed that when the fiberglassducting 84 is folded, as indicated by arrows 86, to form the duct, thehardware subassemblies confront each other in position to form thechannel and it is only necessary to slide a bracket 35 into the waysprovided as hereinabove described as integral parts of the channel barmembers 21 and 22. As is indicated in FIG. 6, a bracket is pushed intoposition at each end of the channel to thereby complete and fastentogether the duct-channel unit.

After thus completing the assembly of the ductchannel unit, it is readyfor mounting in the ceiling grid structure. If an air extractor 58 is tobe used, it may be pushed into position upon ways 28 from one end of thechannel unit after it is inverted since the extractor rests by gravityin the assembly. This may also be done, if preferred. after the unit hasbeen installed in position in the grid structure. The air spreader cap64 is attached to the channel after installation on the grid iscomplete.

As each unit is folded. fastened together by insertion of the bracketsand removed for mounting in the ceiling grid, the next subassembly atthe top of the stack is folded, bracketed and removed until all areassembled into duct-channel units and placed in position in the grid.

The very simple, single operation needed to completely assemble theduct-channel unit requires only a minute or two. Thus. expensive fieldlabor is essentially limited to what can not possibly be done at thefactory; namely. the mounting of the duct-channel units in position inthe ceiling grid structure of the building in which the system is to beinstalled. At the same time, packaging and shipping expenses are minimalby reason of the flat form of the factory subassemblies which makes itpossible to ship without packaging except for the brackets. theair-spreader caps and, if used, the air extractors.

lt will be understood that while the triangular form of duct offersobvious advantages. the duct may be round or have other shape in crosssection, the only requirement being that the two edges carrying thecomponent subassemblies be brought into proximity with each other sothat the channel is formed and fastened together by the brackets.

We claim:

1. The method of making and installing an airdistributing duct-channelunit in the assembled supporting grid of spaced rails of a suspendedceiling which method comprises the steps of providing at a fac torylocation a rectangular sheet of fiberglass ducting. providing twochannel-forming bars each having conformations on a side thereofdefining at least partially enclosed ways and structures for receivingand holding a side edge portion of said ducting, securing at the factorylocation one of said bars on each side of said ducting to form a unitsubassembly, shipping said subassembly to the job location, forming aduct and attached channel at said job location by bending said ductingto bring said channel-forming bars into channel-forming position,inserting a bracket into said ways at each end of the pair of bars tohold the channel together and thus complete assembly of saidair-distributing duct-channel unit. and thereafter installing theduct-channel unit so made in the supporting grid by seating the sameupon rails of said grid for support thereby.

2. The method of claim 1 wherein a plurality of the subassemblies arestacked and fastened together and so shipped to the job location.

3. The method of claim 1 wherein a pair of spaced V grooves are cut intothe top surface of the fiberglass ducting at the factory location toestablish fold lines along which the ducting bends in forming the ductto provide a triangular duct and bring the channelforming bars into thenecessary position to form the channel.

4. The method of claim 1 wherein the bars have inner flanges whichextend toward each other but leave an air gap between them in theassembled channel along the bottom portions thereof and a shutteradapted to vary the size of the gap is mounted upon each of said innerflanges at the factory location.

5. The method of claim 1 wherein a duct retainer adapted to morepositively hold the side edge portions of the ducting in positionrelative to the bar in engagement therewith is inserted between theducting and the bar structure at the factory location.

1. The method of making and installing an air-distributing ductchannelunit in the assembled supporting grid of spaced rails of a suspendedceiling which method comprises the steps of providing at a factorylocation a rectangular sheet of fiberglass ducting, providing twochannel-forming bars each having conformations on a side thereofdefining at least partially enclosed ways and structures for receivingand holding a side edge portion of said ducting, securing at the factorylocation one of said bars on each side of said ducting to form a unitsubassembly, shipping said subassembly to the job location, forming aduct and attached channel at said job location by bending said ductingto bring said channel-forming bars into channel-forming position,inserting a bracket into said ways at each end of the pair of bars tohold the channel together and thus complete assembly of saidair-distributing duct-channel unit, and thereafter installing theduct-channel unit so made in the supporting grid by seating the sameupon rails of said grid for support thereby.
 2. The method of claim 1wherein a plurality of the subassemblies are stacked and fastenedtogether and so shipped to the job location.
 3. The method of claim 1wherein a pair of spaced V grooves are cut into the top surface of thefiberglass ducting at the factory location to establish fold lines alongwhich the ducting bends in forming the duct to provide a triangular ductand bring the channel-forming bars into the necessary position to formthe channel.
 4. The method of claim 1 wherein the bars have innerflanges which extend toward each other but leave an air gap between themin the assembled channel along the bottom portions thereof and a shutteradapted to vary the size of the gap is mounted upon each of said innerflanges at the factory location.
 5. The method of claim 1 wherein a ductretainer adapted to more positively hold the side edge portions of theducting in position relative to the bar in engagement therewith isinserted between the ducting and the bar structure at the factorylocation.